Method for assembling interior rearview mirror assembly

ABSTRACT

A method for assembling a vehicular interior rearview mirror assembly includes providing a mirror mount, a mirror casing, a mirror reflective element at the mirror casing, and a toggle mechanism, which includes a body portion and a toggle lever joined to the body portion. A lower pivot mount of the toggle mechanism is inserted into a lower receiving portion of the mirror casing and an upper pivot mount of the toggle mechanism is inserted into an upper receiving portion of the mirror casing. An outer surface of the body portion corresponds with adjacent outer surfaces of the mirror casing. With a pivot element of the toggle mechanism attached at the mirror mount, and when the toggle lever pivots relative to the lower receiving portion of the mirror casing, the mirror casing pivots relative to the body portion to flip the mirror head between a first orientation and a second orientation.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a division of U.S. patent application Ser.No. 16/747,897, filed Jan. 21, 2020, now U.S. Pat. No. 11,142,126, whichclaims priority of U.S. provisional application Ser. No. 62/915,224,filed Oct. 15, 2019, and U.S. provisional application Ser. No.62/796,612, filed Jan. 25, 2019, which are hereby incorporated herein byreference in their entireties.

FIELD OF THE INVENTION

The present invention relates generally to the field of interiorrearview mirror assemblies for vehicles.

BACKGROUND OF THE INVENTION

It is known to provide a mirror assembly that is adjustably mounted toan interior portion of a vehicle, such as via a double ball pivot orjoint mounting configuration where the mirror casing and reflectiveelement are adjusted relative to the interior portion of a vehicle bypivotal movement about the double ball pivot configuration. The mirrorcasing and reflective element are pivotable about either or both of theball pivot joints by a user that is adjusting a rearward field of viewof the reflective element. It is also generally known to provide aninterior mirror assembly with a prismatic reflective element that may bemanually toggled between daytime and nighttime reflectivity positions.An example of such is described in U.S. Pat. No. 6,318,870, which ishereby incorporated herein by reference in its entirety.

SUMMARY OF THE INVENTION

The present invention provides an interior rearview mirror assembly thatincludes a prismatic reflective element and a mirror casing with atoggle mechanism or assembly that adjusts the viewing angle of theprismatic reflective element. During assembly of the mirror head, thetoggle mechanism is attached at the mirror casing at the front side ofthe mirror head (the side that faces forward relative to the vehiclewhen the mirror assembly is installed in the vehicle). The assembledmirror head is mounted via attachment of a mounting structure or featureof the toggle mechanism at a mounting base or mirror mount that isdisposed at an interior portion of a vehicle so as to pivotally oradjustably mount the mirror head at the mirror mount disposed at theinterior portion of the vehicle.

The present invention also provides an interior rearview mirror assemblyfor a vehicle including a transparent mirror frame. The transparentmirror frame has a patterned front surface and a rear surface oppositethe front surface. A reflective element is attached at the patternedfront surface via adhesive disposed between and the patterned frontsurface of the transparent mirror frame and a rear surface of thereflective element. The patterned front surface includes a pattern ofgrooves to allow air between the adhesive and the patterned frontsurface to escape when the reflective element is attached andlight-refracting or light-reflecting channels. The interior rearviewmirror assembly also includes a mounting assembly mounted at the rearsurface of the transparent mirror frame and configured to mount theinterior rearview mirror assembly at an interior portion of a vehicle.Optionally, the interior rearview mirror assembly includes alight-emitting illumination source disposed at a central region of thetransparent mirror frame of the mounting assembly. The patterned frontsurface may be patterned to reflect and refract light emitted by theillumination source, when powered, so that an illumination pattern isvisible to a person viewing the rear of the transparent mirror frame.

These and other objects, advantages, purposes and features of thepresent invention will become apparent upon review of the followingspecification in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an interior rearview mirror assembly inaccordance with the present invention;

FIGS. 2-4 are perspective views of the interior rearview mirrorassembly;

FIGS. 5 and 6 are exploded perspective views of the mirror head and thetoggle mechanism, shown with the toggle mechanism attached at a two ballmirror mount assembly;

FIGS. 7 and 8 are sectional views of the mirror head, showing themounting of the toggle mechanism at the mirror casing;

FIG. 9 is an exploded perspective view of the two ball mirror mountassembly attached at the rear of the toggle mechanism;

FIG. 10 is an end view of the assembled toggle mechanism and two ballmirror mount assembly;

FIG. 10A is a sectional view of the ball stud and toggle mechanism takenalong the line A-A in FIG. 10;

FIG. 11 is a plan view of the mirror casing;

FIG. 11A is a sectional view of the mirror casing taken along the lineA-A in FIG. 11,

FIG. 11B is an enlarged sectional view of the area B in FIG. 11A;

FIG. 12 is a rear perspective view of a clear or transparent frame lowprofile mirror assembly;

FIG. 12A is a sectional view of a portion of the mirror assembly takenalong the line A-A in FIG. 12;

FIG. 13 is a rear perspective view of the transparent frame of themirror assembly of FIG. 12;

FIG. 13A is a sectional view of a portion of the transparent frame takenalong the line A-A in FIG. 13;

FIG. 14 is a rear plan view of the mirror assembly, with the reflectiveelement adhered to the clear frame;

FIG. 14A is a sectional view of a portion of the mirror assembly takenalong the line A-A in FIG. 14;

FIG. 15 is a rear perspective view of the mirror assembly of FIG. 14;

FIG. 16 is a view showing lamination of the adhesive tape at the framevia a curved stamp;

FIG. 17 is a plan view of the transparent frame with the adhesive tapelaminated thereat;

FIG. 18 is a plan view of the transparent frame with a clear glasssubstrate adhered thereat;

FIG. 19 is a plan view of another transparent frame, showing thetextured pattern at its front surface;

FIG. 19A is a sectional view of the transparent frame taken along theline A-A in FIG. 19, shown with the reflective element bonded at thefront surface;

FIG. 19B is an enlarged view of the upper portion of the transparentframe and reflective element of FIG. 19A;

FIG. 19C is an enlarged view of the area C in FIG. 19B;

FIGS. 20A-C illustrate exemplary patterns for the bonding surface of thetransparent frame, showing different patterns for the area XX in FIG.19;

FIG. 21 is a rear plan view of another transparent frame and reflectiveelement construction, showing an illuminated frame with patterns formedtherein;

FIG. 22 is another rear plan view of the transparent frame andreflective element construction of FIG. 21; and

FIG. 22A is a sectional view of the transparent frame and reflectiveelement construction, taken along the line A-A in FIG. 22.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings and the illustrative embodiments depictedtherein, an interior rearview mirror assembly 10 for a vehicle includesa casing 12 and a reflective element 14 positioned at an interior-facingportion of the casing 12 (FIG. 1). In the illustrated embodiment, themirror assembly 10 is configured to be adjustably mounted to an interiorportion of a vehicle (such as to an interior or in-cabin surface of avehicle windshield or a headliner of a vehicle or the like) via amounting structure or mounting configuration or assembly 30. The mirrorreflective element comprises a prismatic mirror reflective element thatis flipped between a daytime position and a nighttime position via atoggle element or mechanism 18 (discussed below). The mirror assemblymay utilize aspects of the mirror assemblies described in U.S.Publication No. US-2019-0118713, which is hereby incorporated herein byreference in its entirety.

In the illustrated embodiment, the mirror reflective element comprises aprismatic reflective element that is flippable between a daytimeposition and a nighttime position. The mirror assembly comprises areceiving structure 20 at its opposite side for receiving the togglemechanism or structure 18 thereat. As shown in FIGS. 5-8, the togglemechanism 18 is loaded from the forward or windshield side (the sidefacing forward in the vehicle when the mirror assembly is mounted at thevehicle) of the housing (opposite side of the reflective element) duringassembly. The mirror casing 12 includes a bezel portion 22 that receivesand retains the reflective element at the mirror casing. Optionally, themirror assembly may comprise a frameless and/or low profile mirror head(such as by utilizing aspects of the mirror assemblies described in U.S.Publication No. US-2015-0334354, which is hereby incorporated herein byreference in its entirety), with a casing or housing or mirror supportelement that has attachment surfaces at which the mirror reflectiveelement is adhered.

As can be seen in FIGS. 5-7, the receiving structure 20 comprises arecessed area with a pair of upper slots or journals or retainingfeatures 20 a that are configured to receive and retain (e.g., viaflexible anti-backout tabs) upper posts or pins or pivot features 18 aof the toggle mechanism 18. The recessed area also comprises a pair oflower retaining features or journals 20 b that are configured to receiveand retain lower posts or pins 18 b of the toggle mechanism. Thus,during assembly of the mirror, the toggle tab 19 (FIG. 2) is insertedthrough an aperture 12 a of the mirror casing, and the lower hinge pins18 b (above the tab) hook into the journal or retaining features 20 b atthe receiving structure 20 of the housing, and then the toggle mechanismpivots about a pivot axis of the lower hinge pins such that upper posts18 a (on either side above the socket) pivot and snap into the slots orjournals 20 a at the receiving structure 20. Optionally, the aperture atthe lower part of the mirror casing may comprise a slot or recess thatallows the toggle tab to be received thereat via movement of the togglemechanism generally normal to the mirror casing wall (whereby the lowerretaining features may be oriented generally horizontally to allow forsuch movement to move the lower pins into the retaining features). Asshown in FIG. 8, when the toggle mechanism is attached at the mirrorcasing, with the top portion of the toggle seated to the mirror casingupper journal and with the bottom portion of the toggle seated to themirror casing lower journal, the outer upper surface of the togglemechanism is generally flush with the outer upper surface of the mirrorcasing.

Insertion of the toggle mechanism 18 from the back or windshield side(the side facing the vehicle windshield) of the mirror housing can allowfor automation of the assembly process. Also, and as shown in FIGS. 5-7,the housing comprises a recessed area 24 at the center region of thetoggle receiving structure 20. The mirror casing may provide cavities ateither side of the center region, such as for receiving or accommodatinga printed circuit board or other mirror content. As shown in FIG. 8,when the toggle mechanism 18 is attached at the receiving structure 20,the toggle mechanism substantially fills the center region and is at ornear or abutted against the rear of the reflective element.

As shown in FIG. 9, the toggle mechanism 18 includes a post 18 c thatprotrudes from the mirror casing and that is received in a metallic ballstud 26 that pivotally mounts the toggle mechanism and mirror head at amounting assembly 30. The mounting assembly 30 includes a mounting armor tube sub-assembly 32, which comprises a tube 32 a that houses aspring 32 b that is disposed between socket elements 32 c, 32 d, withsocket element 32 c pivotally receiving the ball stud 26 (having, forexample, an 18 mm ball member) and socket element 32 d pivotallyreceiving a ball member (e.g., an 18 mm ball) of a mirror mount 34,which is configured to mount to an interior portion of a vehicle, e.g.,to a mirror mounting button at a windshield of a vehicle (and retainedthereat via a fastener or the like). As also shown in FIG. 9, the togglemechanism may include a pin 36, such as a metal spring pin or the like,that is insert molded into the shaft at the bottom of the toggle tab,e.g. at the pivot axis of the toggle tab. The metal pin may add strengthand rigidity to the toggle mechanism.

The ball stud 26 may comprise a die-cast ball stud (comprising zinc orother suitable material) that is insert molded into the toggle mechanismas shown in FIG. 10A. The toggle mechanism 18 may be molded via atwo-shot molding process or insert mold or over mold such that a stiffermaterial (such as a Polyoxymethylene (POM) or acetal or the like) can beused for the assembly body and post, while a more flexible material(such as a Polypropylene (PP) or the like) may be used for the livinghinge detail at the bottom of the molded toggle mechanism. The stiffermaterial for the main assembly body provides enhanced vibrationstability performance for the mirror and more consistent manual effortsor torque on the ball and socket through temperature variations. Thetoggle body and socket thus may be molded of the stiffer polymericmaterial, and the flexible material may then be molded over the stifferpolymeric material to form the living hinge and other parts of thetoggle mechanism.

As shown in FIG. 10A, the die-case ball stud may be formed with thinwalls at the neck region, such that the ball stud fractures or breaks atthe thinner neck region when the mirror is impacted. The injectionmolded polypropylene post of the toggle mechanism fills the ball studcavity and functions to tether the mirror head to the mounting assemblywhen the ball stud breaks. The mirror assembly may utilize aspects ofthe mirror assemblies described in U.S. Publication No. US-2019-0039519,which is hereby incorporated herein by reference in its entirety.

As shown in FIGS. 11, 11A and 11B, the bezel 22 is formed around theopening of the mirror casing and is formed to receive the prismatic orwedge-shaped glass substrate of the prismatic mirror reflective element14 therein. The bezel lip holds the glass substrate at the mirrorcasing, with the toggle mechanism attached at the opposite side of themirror casing from the bezel and reflective element.

Thus, the toggle mechanism and mirror housing provide for a reduction innumber of parts (no back plate or fasteners needed) and easier assembly,since the toggle mechanism can readily snap into the receiving structureat the rear of the mirror housing.

In the home or daytime reflecting position, the toggle positions themirror reflector surface of the prismatic reflective element 14 at adirect reflection viewing angle, which is intended to reflect more lighttoward the driver. In the actuated or angled or nighttime or glarereflecting position, the toggle positions the mirror reflector surfaceof the prismatic reflective element 14 at an offset reflection viewingangle, which provides a reduced glare and brightness of light reflectedtoward the driver's eyes, relative to the direct reflection viewingangle.

Although shown and described as providing a toggle mechanism forflipping a prismatic mirror reflective element between a daytime ornon-glare reflecting position and a nighttime or glare reflectingposition, the toggle mechanism may function to flip an electro-opticmirror reflective element (such as an electrochromic mirror reflectiveelement having a laminate construction with an electrochromic mediumsandwiched between a front glass substrate and a rear glass substrate)of a dual mode mirror assembly between a mirror reflecting position(where the driver views rearward via viewing reflected images at themirror reflector of the electro-optic mirror reflective element) and avideo display position (where the driver views video images displayedvia a video display screen disposed behind the mirror reflective elementand being viewed through a transflective mirror reflector of the mirrorreflective element).

For example, the toggle mechanism may be utilized with a dual-modeinterior rearview video mirror that can switch from a traditionalreflection mode to a live-video display mode, such as by utilizingaspects of the mirror assemblies and systems described in U.S. Pat. Nos.10,442,360; 10,421,404; 10,166,924 and/or 10,046,706, and/or U.S.Publication Nos. US-2019-0258131; US-2019-0146297; US-2019-0118717and/or US-2017-0355312, and/or U.S. provisional applications, Ser. No.62/945,262, filed Dec. 9, 2019, Ser. No. 62/942,351, filed Dec. 2, 2019,Ser. No. 62/941,089, filed Nov. 27, 2019, and/or Ser. No. 62/942,305,filed Dec. 2, 2019, which are all hereby incorporated herein byreference in their entireties.

In such dual-mode mirror assemblies, a video display screen is disposedbehind substantially the entirety of the active reflective area of themirror reflective element (such as, for example, greater than at least80 percent or greater than at least 90 percent of the active reflectivearea of the mirror reflective element. When the mirror head is flippedto a rearward viewing or reflecting position or orientation, the driverof the vehicle views rearward of the vehicle via viewing reflection oflight incident on the transflective mirror reflector, and when themirror head is flipped to a video display position or orientation, thedriver of the vehicle views video images displayed by the video displayscreen and viewable through the transflective mirror reflector.

Optionally, and with reference to FIGS. 12-18, the toggle mechanism maybe part of a low profile or clear or transparent frame mirror assembly,where the toggle mechanism is attached at the center rear region of aframeless and caseless mirror reflective element. In such a mirrorconstruction, the glass mirror substrate may be received in a clear ortransparent plastic frame. In such a mirror construction, the glasssubstrate is adhered to an attachment surface of the frame via anadhesive tape, which can have air trapped at the glass (due tounevenness of the frame at the glass substrate). The transparent frameor mirror case may be formed to receive the reflective element in arecess, with a rounded lip that circumscribes the attachment surface andthe perimeter edge of the mirror substrate, with the rounded lipproviding a smooth or curved transition between the planar front surfaceof the glass substrate and a less-curved portion of the side surface ofthe lip and mirror frame, and with no part of the lip encroaching on oroverlapping the planar front surface of the mirror substrate.Optionally, the perimeter region of the glass substrate may comprise arounded surface, whereby the frame or case does not include thecircumscribing lip and the rounded surface of the glass substrateprovides the smooth transition between the planar front surface of theglass substrate and the side surface of the mirror frame. The mirrorassembly may utilize aspects of the mirror assemblies described in U.S.Publication No. US-2019-0258131, which is hereby incorporated herein byreference in its entirety. The frame may be formed by a polymeric orplastic injection molding process, such as by injection molding alight-transmitting transparent polymeric material, such as a transparentor translucent polycarbonate material or a transparent or translucentpolyacrylate material or the like.

In the illustrated embodiment of FIGS. 12-15, the mirror assemblycomprises a transparent frame 112 that is formed to receive a mirrorreflective element 114 thereat (such as in a recess formed at theinterior or driver-facing side of the transparent frame). The togglemechanism 118 attaches at the rear or opposite side of the transparentframe and pivotally mounts the mirror head at a mounting assembly 130.The transparent frame 112 (at which the reflective element 114 is bondedvia an adhesive tape 113) has its bonding surface formed with a texturedpattern, such as a rhombus pattern or square pattern or honey-combpattern or the like, with grooves 112 a (FIG. 13A) formed in thatpattern across the bonding surface. Thus, any air trapped between theadhesive tape and the bonding surface can escape along the grooves.

Optionally, and such as shown in FIG. 16, the adhesive tape 113 may beadhered or laminated onto the frame using a curved stamp 121, in orderto further allow for air to escape during the bonding or laminatingprocess. As shown in FIG. 17, with the adhesive tape bonded in theframe, the square-structure or pattern of the bonding surface of theframe emerges into the tape to provide enhanced bonding of the glasssubstrate at the tape. As shown in FIG. 18, only small areas of theadhesive tape do not contact the mirror glass substrate (shown in FIG.18 without a mirror reflector so that the adhesive tape is viewablethrough the substrate), and such small areas would not be visiblethrough the mirror reflector to a person viewing the mirror assembly.

Referring now to FIGS. 19 and 19A-C, a transparent frame 212 includes atextured pattern at its front surface 212 a with a perimeter lip 212 bthat circumscribes the reflective element 214 and that comprises arounded exterior curved surface that does not encroach or overlap thefront surface 214 a of the reflective element. As shown in FIG. 19A, theperimeter lip 212 b of frame 212 provides a rounded curved transitionfrom the planar front surface 214 a of the reflective element 214, witha rear perimeter region 212 c of the frame providing a rounded curvedtransition from a side region of the frame and lip to a generally planarrear surface 212 d of the frame 212. The reflective element 214 thus isnested within the frame 212 and bonded to the front surface 212 a viathe adhesive tape 213. When the reflective element 214 is bonded to thetextured front surface 212 a of the frame 212, air can escape throughthe recessed structure to provide enhanced and uniform bonding of thetape 213 with the front surface 212 a of the frame 212.

The textured pattern at the front surface 212 a of the frame maycomprise any suitable pattern that has a plurality of grooves orchannels formed at the front surface. For example, the pattern maycomprise a rectangular pattern or a rhombus pattern or structure (seeFIGS. 19 and 20A), or the pattern may comprise a honeycomb structure(FIG. 20B), or the pattern may comprise a linear pattern or structure(FIG. 20C). The pattern is established over the entire bonding surface212 a, with the exception of mounting apertures or structure 215established at or near a center region of the frame for attaching themounting assembly (such as a mounting assembly including a toggleassembly such as shown in FIG. 15) thereat.

Optionally, the transparent frame may provide a pattern such as a logoor icon or alphanumeric character or the like, with the pattern beingilluminated by a light source to provide a glow or illumination of thepattern and/or a perimeter region of the frame. For example, and such asshown in FIGS. 21, 22 and 22A, a transparent frame 312 includes apatterned surface 312 a and the mounting assembly or structure 318includes an illumination source 340 (FIG. 22A) disposed within a housing318 a. The patterned bonding surface 312 a provides enhanced bonding ofthe adhesive 313 at the frame 312 to attach the reflective element 314to the frame, such as in a similar manner as discussed above.

In the illustrated embodiment, the illumination source 340 (such as alight emitting diode (LED) or the like) is disposed at a circuit elementor circuit board 341 (FIG. 22A) disposed at a central region of theframe and at a protruding portion 312 e of the frame (such as with thecircuit element 341 received in a recess at the rearward end of theprotruding portion 312 e), with the frame having a larger channel orindent or notch 312 f in front of the LED 340 to reflect light emittedby the LED in directions parallel to the front surface 312 a and rearsurface 312 d of the frame. The notch 312 f may comprise aconical-shaped notch so that light emitted by the LED 340 reflectsradially outward from the conical-shaped notch to provide illuminationalong and around the periphery of the transparent frame 312. Optionally,one or more notches may be disposed in the path of the light emitted bythe LED to provide the desired reflection and spreading of the lightalong and within the transparent frame. Optionally, the notch or notchesmay have a reflective coating or element disposed thereat to enhancereflection of the light along and within the transparent frame.

As shown in FIG. 22 the textured pattern at the front or bonding surface312 a of the transparent frame 312 includes notches or channels (thatform the desired pattern or icon or logo) that are deep enough into thetransparent frame so that light emitted by the LED 340 and reflected bythe notch 312 f is incident at the patterned notches, whereby the lightis reflected and refracted so as to provide edge illumination of thetexture or pattern. Thus, the texture or pattern is illuminated or glowswhen the LED 340 is electrically powered or activated or energized, suchthat a person viewing the transparent frame can see the illuminatedpattern and icon or logo or the like. The LED 340 may be electricallypowered or activated or energized responsive to a user input and/or toan ambient light sensor (where the LED is activated when the sensordetermines that the ambient light level is below a threshold value) orthe like.

Thus, and as best shown in FIG. 22A, light emitted by the LED 340 passesalong the protrusion 312 e so as to be incident at the surface of thenotch 312 f, whereby the light is reflected in directions generallyparallel to the front and rear surfaces of the transparent frame. Theprotrusion 312 e and/or the circuit element may include non-lighttransmitting features or light guiding features so that the lightemitted by the LED is directed generally toward the notch 312 f and notradially outward from the protrusion 312 e. The light that is reflectedby the notch 312 f passes through and within the transparent frame in adirection generally parallel to the front and rear surfaces of the frameuntil the light is incident at the notches or patterned channels of thepattern or icon, whereby the light reflects and refracts so as to bevisible at those areas to a person viewing the rear side 312 d (FIG.22A) of the transparent frame.

In the illustrated embodiment, the pattern comprises linear channelsthat are illuminated by light emitted by the LED, where the light may beguided along the linear channels to provide a glow along the channels.The icon or logo has channels formed that are transverse to thedirection of the light passing along and within the transparent frameand thus may reflect and refract the light further to provide a greaterintensity of illumination at the icon or logo as compared to theintensity of illumination along the linear channels. The depth of thenotches or channels may be selected to provide a desired amount ofillumination, and different portions of the pattern may comprise deeperchannels or notches to provide portions where the illumination isgreater than other areas of the pattern. Light that passes along andwithin the transparent frame that is not reflected or refracted by thenotches or channels is visible at the periphery of the transparent frameto provide a circumferential glow around the perimeter of the frame.When the LED 340 is not electrically powered or energized, the patternmay still be visible through the transparent frame to a person viewingthe rear surface of the transparent frame.

The illumination source or LED may comprise a white light-emitting LEDor a monochromatic or colored light-emitting LED (such as a redlight-emitting LED or blue light-emitting LED or green light-emittingLED or the like) to provide the desired appearance of the mirror frame,when the LED is electrically powered. Optionally, the LED may comprise amulti-colored LED that is electrically operable or energizable orpowerable to emit a variety of colors responsive to a control input orpower level at the LED, such that a user can select the color of lightthat is to be emitted by the LED for the desired or customized orpersonalized appearance of the mirror frame. Optionally, the transparentframe may be tinted or colored or the grooves or channels may be tintedor colored to provide a desired color effect to the mirror frame whenthe LED is powered.

The reflective element and mirror casing are adjustable relative to abase portion or mounting assembly to adjust the driver's rearward fieldof view when the mirror assembly is normally mounted at or in thevehicle. The sockets and ball members of the mounting structure mayutilize aspects of the pivot mounting assemblies described in U.S. Pat.Nos. 6,318,870; 6,593,565; 6,690,268; 6,540,193; 4,936,533; 5,820,097;5,100,095; 7,249,860; 6,877,709; 6,329,925; 7,289,037; 7,249,860 and/or6,483,438, and/or U.S. Publication No. US-2018-0297526, which are herebyincorporated herein by reference in their entireties.

The mirror assembly may comprise any suitable construction, such as, forexample, a mirror assembly with the reflective element being nested inthe mirror casing and with a bezel portion that circumscribes aperimeter region of the front surface of the reflective element, or withthe mirror casing having a curved or beveled perimeter edge around thereflective element and with no overlap onto the front surface of thereflective element (such as by utilizing aspects of the mirrorassemblies described in U.S. Pat. Nos. 7,255,451; 7,289,037; 7,360,932;8,049,640; 8,277,059 and/or 8,529,108, which are hereby incorporatedherein by reference in their entireties) or such as a mirror assemblyhaving a rear substrate of an electro-optic or electrochromic reflectiveelement nested in the mirror casing, and with the front substrate havingcurved or beveled perimeter edges, or such as a mirror assembly having aprismatic reflective element that is disposed at an outer perimeter edgeof the mirror casing and with the prismatic substrate having curved orrounded perimeter edges, such as described in U.S. Pat. Nos. 8,508,831;8,730,553; 9,598,016 and/or 9,346,403, and/or U.S. Publication Nos.US-2014-0313563 and/or US-2015-0097955, which are hereby incorporatedherein by reference in their entireties (and with electrochromic andprismatic mirrors of such construction are commercially available fromthe assignee of this application under the trade name INFINITY™ mirror).

The prismatic mirror assembly may be mounted or attached at an interiorportion of a vehicle (such as at an interior surface of a vehiclewindshield) via the mounting means described above, and the reflectiveelement may be toggled or flipped or adjusted between its daytimereflectivity position and its nighttime reflectivity position via anysuitable toggle means, such as by utilizing aspects of the mirrorassemblies described in U.S. Pat. Nos. 6,318,870 and/or 7,249,860,and/or U.S. Publication No. US-2010-0085653, which are herebyincorporated herein by reference in their entireties. The interiorprismatic reflective element may utilize aspects of the reflectiveelements and mirror assemblies described in U.S. Pat. Nos. 7,420,756;7,338,177; 7,289,037; 7,274,501; 7,255,451; 7,249,860; 6,598,980;6,318,870; 5,327,288; 4,948,242; 4,826,289; 4,436,371 and/or 4,435,042,which are hereby incorporated herein by reference in their entireties. Avariety of mirror accessories and constructions are known in the art,such as those disclosed in U.S. Pat. Nos. 5,555,136; 5,582,383;5,680,263; 5,984,482; 6,227,675; 6,229,319 and/or 6,315,421 (which arehereby incorporated herein by reference in their entireties), that canbenefit from the present invention.

The mirror assembly may comprise or utilize aspects of other types ofcasings or the like, such as described in U.S. Pat. Nos. 7,338,177;7,289,037; 7,249,860; 6,439,755; 4,826,289 and/or 6,501,387, which areall hereby incorporated herein by reference in their entireties, withoutaffecting the scope of the present invention. For example, the mirrorassembly may utilize aspects of the flush or frameless or bezellessreflective elements described in U.S. Pat. Nos. 7,626,749; 7,360,932;7,289,037; 7,255,451; 7,274,501 and/or 7,184,190, which are all herebyincorporated herein by reference in their entireties.

Optionally, the interior rearview mirror assembly may include circuitrytherein (such as at a printed circuit board or the like disposed withinthe mirror casing, and electrical connection to the circuitry may bemade via an electrical lead or connector of a wiring harness of thevehicle. Optionally, the electrical connector may be received throughthe mirror casing and through an aperture established through the toggleelement, such as by utilizing aspects of the mirror assemblies describedin U.S. Pat. No. 5,798,688 and/or U.S. Publication No. US-2010-0085653,which are hereby incorporated herein by reference in their entireties.

Changes and modifications in the specifically described embodiments maybe carried out without departing from the principles of the presentinvention, which is intended to be limited only by the scope of theappended claims as interpreted according to the principles of patentlaw.

1. A method for assembling a vehicular interior rearview mirrorassembly, the method comprising: providing a mirror mount configured formounting at an interior portion of a vehicle; providing a mirror casing,wherein the mirror casing comprises an upper receiving portion and alower receiving portion; accommodating a mirror reflective element atthe mirror casing; providing a toggle mechanism comprising (i) a bodyportion and (ii) a toggle lever joined to the body portion; insertingthe toggle lever through an aperture established through a lower regionof the mirror casing; moving the toggle mechanism to insert a lowerpivot mount of the toggle mechanism into the lower receiving portion ofthe mirror casing; pivoting the toggle mechanism about the lower pivotmount to insert an upper pivot mount of the toggle mechanism into theupper receiving portion of the mirror casing; and wherein, when theupper and lower pivot mounts of the toggle mechanism are inserted intothe respective upper and lower receiving portions of the mirror casing,an outer surface of the body portion corresponds with adjacent outersurfaces of the mirror casing, and, when the toggle lever pivotsrelative to the lower receiving portion of the mirror casing, the mirrorcasing pivots relative to the body portion to, when a pivot element ofthe toggle mechanism is pivotally attached at the mirror mount and whenthe mirror mount is mounted at the interior portion of the vehicle, flipthe mirror reflective element between a first orientation and a secondorientation.
 2. The method of claim 1, wherein providing the togglemechanism comprises injection molding the toggle mechanism from apolymeric material.
 3. The method of claim 2, wherein injection moldingthe toggle mechanism comprises insert molding a pivot pin at the togglelever.
 4. The method of claim 2, wherein injection molding the togglemechanism comprises insert molding the pivot element at the body portionof the toggle mechanism.
 5. The method of claim 4, wherein injectionmolding the toggle mechanism comprises molding a post of the togglemechanism into a cavity of the pivot element.
 6. The method of claim 4,wherein the pivot element comprises a ball element that is pivotallyreceived in a socket element of the mirror mount.
 7. The method of claim1, wherein accommodating the mirror reflective element at the mirrorcasing comprises receiving a perimeter edge region of the mirrorreflective element in a groove established along a periphery of themirror casing.
 8. The method of claim 7, wherein, with the perimeteredge region of the mirror reflective element received in the groove, abezel portion of the mirror casing overlaps and circumscribes aperiphery of a front surface of the mirror reflective element.
 9. Themethod of claim 1, wherein accommodating the mirror reflective elementat the mirror casing comprises adhesively attaching the mirrorreflective element at an attaching portion of the mirror casing.
 10. Themethod of claim 9, wherein the attaching portion of the mirror casingcomprises a pattern of grooves established thereat to allow air betweenthe adhesive and the attaching portion to escape when the mirrorreflective element is adhesively attached at the mirror casing.
 11. Themethod of claim 10, wherein the mirror casing comprises a transparentmirror frame.
 12. The method of claim 1, wherein the mirror reflectiveelement comprises a prismatic mirror reflective element, and wherein thefirst orientation comprises a daytime reflecting orientation and thesecond orientation comprises a nighttime reflecting orientation.
 13. Themethod of claim 1, wherein the mirror reflective element comprises anelectrochromic mirror reflective element having a transflective mirrorreflector, and wherein the first orientation comprises a rearwardviewing reflecting orientation and the second orientation comprises avideo display orientation, and wherein a video display screen isdisposed behind the electrochromic mirror reflective element andoperates to display video images for viewing at the electrochromicmirror reflective element when the mirror reflective element is flippedto the video display orientation.
 14. A vehicular interior rearviewmirror assembly assembled via the method of claim
 1. 15. The method ofclaim 1, wherein providing the mirror casing comprises providing atransparent mirror frame having a patterned front side having aplurality of channels established thereat, and a rear side opposite thepatterned front side.
 16. The method of claim 15, further comprisingproviding an illumination source, wherein the patterned front side ofthe transparent mirror frame is patterned to reflect and refract lightemitted by the illumination source, when powered, so that anillumination pattern is visible to a person viewing the rear of thetransparent mirror frame.
 17. The method of claim 16, wherein theillumination source is disposed at a central region of the transparentmirror frame and light emitted by the illumination source, when powered,is reflected by structure at the patterned front side so that thereflected light passes along and within the transparent mirror frame ina direction along the rear side of the transparent mirror frame.
 18. Themethod of claim 17, wherein the structure comprises a conical-shapedelement to radially reflect light in directions around the structure andparallel to the rear side of the transparent mirror frame.
 19. Themethod of claim 17, wherein the patterned front side comprises an iconthat is formed by channels that, when the illumination source ispowered, reflect and refract light to illuminate the icon.
 20. Themethod of claim 17, wherein some of the reflected light passing alongand within the transparent mirror frame is reflected and refracted bychannels of the patterned front side and some of the reflected lightpasses along and within the transparent mirror frame so as to illuminatea perimeter region of the transparent mirror frame.
 21. The method ofclaim 15, wherein the transparent mirror frame comprises a perimeter lipthat extend around a periphery of the patterned front side, and whereinthe perimeter lip circumscribes a peripheral edge of the mirrorreflective element, and wherein the perimeter lip has an outer curvedsurface that provides a curved transition between a planar front surfaceof the mirror reflective element and a side surface of the transparentmirror frame, and wherein the perimeter lip does not overlap any part ofthe planar front surface of the mirror reflective element.
 22. A methodfor assembling a vehicular interior rearview mirror assembly, the methodcomprising: providing a mirror mount configured for mounting at aninterior portion of a vehicle; providing a transparent mirror framehaving a patterned front side having a plurality of channels establishedthereat, and a rear side opposite the patterned front side;accommodating a mirror reflective element at the transparent mirrorframe; wherein the transparent mirror frame and the mirror reflectiveelement accommodated thereat comprise a mirror head; providing anillumination source at the mirror head; wherein the patterned front sideof the transparent mirror frame is patterned to reflect and refractlight emitted by the illumination source, when powered, so that anillumination pattern is visible to a person viewing the rear of thetransparent mirror frame; and pivotally mounting the mirror head at themirror mount.
 23. The method of claim 22, further comprising (i)providing a toggle mechanism comprising a body portion and a togglelever joined to the body portion, (ii) inserting the toggle leverthrough an aperture established through a lower region of thetransparent mirror frame, (iii) moving the toggle mechanism to insert alower pivot mount of the toggle mechanism into the lower receivingportion of the transparent mirror frame, and (iv) pivoting the togglemechanism about the lower pivot mount to insert an upper pivot mount ofthe toggle mechanism into the upper receiving portion of the transparentmirror frame, wherein, when the toggle lever pivots relative to thelower receiving portion of the transparent mirror frame, the mirrorreflective element adjusts relative to the mirror mount between a firstorientation and a second orientation.
 24. The method of claim 22,wherein accommodating the mirror reflective element at the transparentmirror frame comprises adhesively attaching the mirror reflectiveelement at an attaching portion of the transparent mirror frame.
 25. Themethod of claim 24, wherein the attaching portion of the transparentmirror frame comprises a pattern of grooves established thereat to allowair between the adhesive and the attaching portion to escape when themirror reflective element is adhesively attached at the transparentmirror frame.
 26. The method of claim 22, wherein the illuminationsource is disposed at a central region of the transparent mirror frameand light emitted by the illumination source, when powered, is reflectedby structure at the patterned front side so that the reflected lightpasses along and within the transparent mirror frame in a directionalong the rear side of the transparent mirror frame.
 27. The method ofclaim 26, wherein the structure comprises a conical-shaped element toradially reflect light in directions around the structure and parallelto the rear side of the transparent mirror frame.
 28. The method ofclaim 26, wherein the patterned front side comprises an icon that isformed by channels that, when the illumination source is powered,reflect and refract light to illuminate the icon.
 29. The method ofclaim 26, wherein some of the reflected light passing along and withinthe transparent mirror frame is reflected and refracted by channels ofthe patterned front side and some of the reflected light passes alongand within the transparent mirror frame so as to illuminate a perimeterregion of the transparent mirror frame.
 30. The method of claim 22,wherein the transparent mirror frame comprises a perimeter lip thatextend around a periphery of the patterned front side, and wherein theperimeter lip circumscribes a peripheral edge of the mirror reflectiveelement, and wherein the perimeter lip has an outer curved surface thatprovides a curved transition between a planar front surface of themirror reflective element and a side surface of the transparent mirrorframe, and wherein the perimeter lip does not overlap any part of theplanar front surface of the mirror reflective element.
 31. A vehicularinterior rearview mirror assembly assembled via the method of claim 22.32. A method for assembling a vehicular interior rearview mirrorassembly, the method comprising: providing a mirror mount configured formounting at an interior portion of a vehicle; providing a mirror casing,wherein the mirror casing comprises an upper receiving portion and alower receiving portion; accommodating a mirror reflective element atthe mirror casing; providing a toggle mechanism comprising (i) a bodyportion and (ii) a toggle lever joined to the body portion; whereinproviding the toggle mechanism comprises injection molding the togglemechanism from a polymeric material; wherein injection molding thetoggle mechanism comprises insert molding a pivot pin at the togglelever; wherein injection molding the toggle mechanism comprises insertmolding a pivot element at the body portion; inserting the toggle leverthrough an aperture established through a lower region of the mirrorcasing; moving the toggle mechanism to insert a lower pivot mount of thetoggle mechanism into the lower receiving portion of the mirror casing;pivoting the toggle mechanism about the lower pivot mount to insert anupper pivot mount of the toggle mechanism into the upper receivingportion of the mirror casing; and wherein, when the upper and lowerpivot mounts of the toggle mechanism are inserted into the respectiveupper and lower receiving portions of the mirror casing, an outersurface of the body portion corresponds with adjacent outer surfaces ofthe mirror casing, and, when the toggle lever pivots relative to thelower receiving portion of the mirror casing, the mirror casing pivotsrelative to the body portion to, when the pivot element of the bodyportion of the toggle mechanism is pivotally attached at the mirrormount and when the mirror mount is mounted at the interior portion ofthe vehicle, flip the mirror reflective element between a firstorientation and a second orientation.
 33. The method of claim 32,wherein injection molding the toggle mechanism comprises molding a postof the toggle mechanism into a cavity of the pivot element.
 34. Themethod of claim 32, wherein the pivot element comprises a ball elementthat is pivotally received in a socket element of the mirror mount. 35.The method of claim 32, wherein accommodating the mirror reflectiveelement at the mirror casing comprises adhesively attaching the mirrorreflective element at an attaching portion of the mirror casing.
 36. Themethod of claim 35, wherein the attaching portion of the mirror casingcomprises a pattern of grooves established thereat to allow air betweenthe adhesive and the attaching portion to escape when the mirrorreflective element is adhesively attached at the mirror casing.
 37. Themethod of claim 36, wherein the mirror casing comprises a transparentmirror frame.
 38. A vehicular interior rearview mirror assemblyassembled via the method of claim 32.